Hot melt adhesive supply and methods associated therewith

ABSTRACT

A flexible bag system can dispense particulate hot melt adhesive. The flexible bag system includes an articulation device in contact with the flexible bag body and manipulates the flexible bag body to maintain fluidity of the particulate hot melt adhesive out of the outlet. A system for supplying particulate hot melt adhesive is also disclosed. The system includes an outer housing, a flexible inner housing disposed inside the outer housing that receives the particulate hot melt adhesive, a transfer opening disposed inside the flexible inner housing and through which the particulate hot melt adhesive is transferred, and an agitator in contact with the flexible inner housing, where the agitator applies a lateral force to a surface of the flexible inner housing.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent ApplicationNo. 62/115,964, filed Feb. 13, 2015, which is incorporated herein byreference in its entirety.

FIELD OF THE INVENTION

The present invention generally relates to hot melt adhesive systems.

BACKGROUND

Hot melt adhesive systems have many applications in manufacturing andpackaging. For example, thermoplastic hot melt adhesives are used forcarton sealing, case sealing, tray forming, pallet stabilization,nonwoven applications including diaper manufacturing, and many otherapplications. Hot melt adhesives often come in the form of solid orsemi-solid pellets or particulates. These hot melt adhesive particulatesare melted into a liquid form by a melter, and the liquid hot meltadhesive is ultimately applied to an object such as a work piece,substrate or product by a dispensing device suitable to the application.

A supply of unmelted hot melt adhesive pieces (referred to variouslyherein as “particulate hot melt adhesive,” “hot melt adhesiveparticulate,” “adhesive particulate”, or simply “particulate”) must bemaintained and delivered to the melter in order for the melter toproduce the liquid hot melt adhesive used by the dispensing device. Forexample, it is known for a person to employ a scoop or bucket toretrieve hot melt adhesive particulate from a bulk supply, and todeliver the particulate to a melter. Typically, this involves filling ahopper or other container associated with the melter one scoop of hotmelt adhesive particulate at a time. This requires the person to handlethe hot melt adhesive particulate closely, which may be undesirablebecause hot melt adhesive dust may be stirred up during handling. Inaddition, transferring hot melt adhesive particulate in this manner isprone to waste caused by spillage.

Other challenges relate to issues surrounding the propensity forparticulates of hot melt adhesive to become stuck together under certainstorage and use conditions. If particulates stick or agglomeratetogether, it becomes difficult to feed the particulate into a hopperand/or into an associated melter tank. Once the particulates are in thehopper associated with a melter tank, and the hopper is separated fromthe melter tank by a particulate feed device, clumping and sticking ofparticulates can be caused by heat emanating from the melter tank.Therefore, improvements generally related to these and related areas ofhot melt adhesive dispensing systems are needed.

SUMMARY

In a first illustrative embodiment, the invention provides a melter forheating and melting particulate hot melt adhesive into a liquefied form.The melter includes a heated receiving device having an interior with aninlet configured to receive the particulate hot melt adhesive and anoutlet, the heated receiving device operative to heat and melt theparticulate hot melt adhesive, and direct the hot melt adhesive as aliquefied form to the outlet. A flexible hopper is configured to hold asupply of the particulate hot melt adhesive. A particulate hot meltadhesive feed device allows the particulate hot melt adhesive to bedirected from the flexible hopper to the inlet of the heated receivingdevice.

The melter may have various alternative or additional aspects orcomponents. For example, the flexible hopper further comprises a bag,and the bag may be formed of any suitable material for the applicationneeds. One advantageous material is fabric, such as any strong woven ornonwoven material that can hold particulate hot melt adhesive. Theflexible hopper further comprises at least a first section that can bearticulated relative to another section to move particulate adjacent toa wall of the flexible hopper toward a central interior location of theflexible hopper.

In another embodiment, the invention provides a melter for heating andmelting particulate hot melt adhesive into a liquefied form, including aheated receiving device having an interior with an inlet configured toreceive the particulate hot melt adhesive and an outlet. The heatedreceiving device is operative to heat and melt the particulate hot meltadhesive, and direct the hot melt adhesive as a liquefied form to theoutlet. A flexible hopper is configured to hold a supply of theparticulate hot melt adhesive. An articulation device includes a drivenelement operative to move the particulate hot melt adhesive held in theflexible hopper. A particulate hot melt adhesive feed device allows theparticulate hot melt adhesive to be directed from the flexible hopper tothe inlet of the heated receiving device. This embodiment, as with theremaining embodiments, may also have alternative or additional aspectsand/or components, such as described herein.

The flexible hopper further comprises movable wall portions and anarticulation device moves the wall portions to move the particulate hotmelt adhesive held in the flexible hopper. The articulation device maybe operatively coupled to the interior and/or exterior of the movablewall portions associated with the flexible hopper.

In another embodiment, the invention provides a melter for heating andmelting particulate hot melt adhesive into a liquefied form, including aheated receiving device having an interior with an inlet configured toreceive the particulate hot melt adhesive and an outlet. The heatedreceiving device is operative to heat and melt the particulate hot meltadhesive, and direct the hot melt adhesive as a liquefied form to theoutlet. A hopper is configured to hold a supply of the particulate hotmelt adhesive. A driven device is positioned within the hopper. Thedriven device is capable of moving to thereby move the particulate hotmelt adhesive within the hopper. A particulate hot melt adhesive feeddevice allows the particulate hot melt adhesive to be directed from thehopper to the inlet of the heated receiving device. The driven devicemay take on any suitable form. For example, the driven device mayfurther comprise at least one rotating element configured to stir theparticulate hot melt adhesive.

In another embodiment, the invention provides a melter for heating andmelting particulate hot melt adhesive into a liquefied form, including aheated receiving device having an interior with an inlet configured toreceive the particulate hot melt adhesive and an outlet. The heatedreceiving device is operative to heat and melt the particulate hot meltadhesive, and direct the hot melt adhesive as a liquefied form to theoutlet. A hopper is configured to hold a supply of the particulate hotmelt adhesive. A particulate hot melt adhesive feed device includes adriven feed element operative to move the particulate hot melt adhesivefrom the hopper to the inlet of the heated receiving device. A coverelement is mounted for movement adjacent to the inlet of the heatedreceiving device between an open condition and a closed condition. Thecover element is in the open condition when the feed device is activatedto move the particulate hot melt adhesive to the inlet, and the coverelement is in the closed condition when the feed device is not movingthe particulate hot melt adhesive to the inlet. The driven feed elementmay take any suitable form. As examples, the feed element may furthercomprise at least one of: a rotating wheel, an auger, or a conveyor. Thecover element may, for example, be heated and in the closed conditionparticulate hot melt adhesive will melt and flow past the cover elementinto the interior of the heated receiving device.

In another embodiment, the invention provides a melter for heating andmelting particulate hot melt adhesive into a liquefied form, including aheated receiving device having an interior with an inlet configured toreceive the particulate hot melt adhesive and an outlet. The heatedreceiving device is operative to heat and melt the particulate hot meltadhesive, and direct the hot melt adhesive as a liquefied form to theoutlet. A hopper is configured to hold a supply of the particulate hotmelt adhesive. A particulate hot melt adhesive feed device includes adriven feed element operative to move the particulate hot melt adhesivefrom the hopper to the inlet of the heated receiving device. An airmover device is positioned proximate the inlet opening of the heatedreceiving device, and the air mover device directs air across the inletopening.

In another embodiment, the invention provides a melter for heating andmelting particulate hot melt adhesive into a liquefied form, including aheated receiving device having an interior with an inlet configured toreceive the particulate hot melt adhesive and an outlet. The heatedreceiving device is operative to heat and melt the particulate hot meltadhesive, and direct the hot melt adhesive as a liquefied form to theoutlet. A prepackaged container is provided and holds a supply of theparticulate hot melt adhesive. The prepackaged container includes anoutlet. A particulate hot melt adhesive feed device allows theparticulate hot melt adhesive to be directed from the outlet of theprepackaged container to the inlet of the heated receiving device.

The prepackaged container may take many forms. As examples, theprepackaged container can further comprise a bag and, therefore, beflexible. Or, the prepackaged container may comprise a rigid container.Even when the container comprises a bag, it may include rigid portionsfor support and/or at various locations such as at the outlet. A coveris provided on the outlet of the prepackaged container, and the cover iscapable of being opened for establishing a flow path for the particulatehot melt adhesive through the outlet of the prepackaged container. Forexample, the cover may comprise a rupturable element that opens whenmounted to the melter, such as by a piercing element. Alternatively, thecover may be manually or automatically opened during or after a processused to connect the prepackaged container to the melter.

In another embodiment, the invention provides a melter for heating andmelting particulate hot melt adhesive into a liquefied form, including aheated receiving device having an interior with an inlet configured toreceive the particulate hot melt adhesive and an outlet. The heatedreceiving device is operative to heat and melt the particulate hot meltadhesive, and direct the hot melt adhesive as a liquefied form to theoutlet. A container mounting component is positioned adjacent the heatedreceiving device. A prepackaged container is directly connected to thecontainer mounting component and holds a supply of the particulate hotmelt adhesive. The prepackaged container includes an outlet. Theprepackaged container is capable of being connected to and disconnectedfrom the container mounting component to allow removal of oneprepackaged container and replacement by a different prepackagedcontainer. A particulate hot melt adhesive feed device allows theparticulate hot melt adhesive to be directed from the outlet of theprepackaged container to the inlet of the heated receiving device. Theprepackaged container may have various alternative or additionalfeatures or components, such as described herein as examples.

In another embodiment, the invention provides a flexible hopperconfigured to hold a supply of the particulate hot melt adhesive for usewith a melter for heating and melting particulate hot melt adhesive intoa liquefied form. The flexible hopper comprises at least one side walldefining an interior for holding the particulate hot melt adhesive. Theside wall includes at least a first section that can be moved relativeto another section to move particulate adjacent to a wall of theflexible hopper toward a central interior location of the flexiblehopper. An outlet of the flexible hopper is in communication with theinterior. A coupling element is configured to connect the outlet with aparticulate hot melt adhesive feed device of the melter. The flexiblehopper may have various additional or alternative features orcomponents, such as those described herein.

In another aspect, the invention provides various methods. For example,a method is provided for heating and melting particulate hot meltadhesive into a liquefied form. The method includes holding a supply ofthe particulate hot melt adhesive in a flexible hopper including anoutlet coupled in fluid communication with a pathway leading to an inletof a heated receiving device. Particulate hot melt adhesive is fed fromthe outlet of the flexible hopper through the inlet of the heatedreceiving device. The particulate hot melt adhesive is heated and meltedin an interior of the heated receiving device. Liquefied hot meltadhesive is directed from the interior of the heated receiving device toan outlet of the heated receiving device. The liquefied hot meltadhesive is directed from the outlet to a hot melt adhesive dispenser.

This method, as well as the other methods disclosed herein may havevarious additional or alternative aspects or steps. For example,agglomerated masses of the particulate hot melt adhesive in the flexiblehopper may be broken apart by 1) moving at least one wall portion of theflexible hopper relative to another wall portion of the flexible hopperand/or 2) moving a device within the flexible hopper configured tocontact and break apart the agglomerated masses.

Another method for heating and melting particulate hot melt adhesiveinto a liquefied form includes holding a supply of the particulate hotmelt adhesive in a flexible hopper including an outlet coupled in fluidcommunication with a pathway leading to an inlet of a heated receivingdevice. The particulate hot melt adhesive in the flexible hopper ismoved by a device within the flexible hopper. The particulate hot meltadhesive is fed from the outlet of the flexible hopper through the inletof the heated receiving device. The particulate hot melt adhesive isheated and melted in an interior of the heated receiving device.Liquefied hot melt adhesive is directed from the interior of the heatedreceiving device to an outlet of the heated receiving device. Theliquefied hot melt adhesive is pumped from the outlet to a hot meltadhesive dispenser.

Moving the particulate hot melt adhesive further comprises rotating thedevice within the flexible hopper. Moving the particulate hot meltadhesive can further or alternatively comprise moving at least one wallportion of the flexible hopper with respect to another wall portion ofthe flexible hopper.

Another method for heating and melting particulate hot melt adhesiveinto a liquefied form includes holding a supply of the particulate hotmelt adhesive in a flexible hopper including an outlet coupled in fluidcommunication with a pathway leading to an inlet of a heated receivingdevice. At least one wall portion of the flexible hopper is moved withrespect to another wall portion of the flexible hopper. The particulatehot melt adhesive is fed from the outlet of the flexible hopper throughthe inlet of the heated receiving device. The particulate hot meltadhesive is heated and melted in an interior of the heated receivingdevice. Liquefied hot melt adhesive is directed from the interior of theheated receiving device to an outlet of the heated receiving device. Theliquefied hot melt adhesive is pumped from the outlet to a hot meltadhesive dispenser.

Moving the particulate hot melt adhesive in the flexible hopper furthercomprises engaging an interior surface of the wall portion with a drivendevice and moving the wall portion inward and outward. Moving theparticulate hot melt adhesive in the flexible hopper can further oralternatively comprise engaging an exterior surface of the wall portionwith a driven device and moving the wall portion inward and outward.

Another method for heating and melting particulate hot melt adhesiveinto a liquefied form includes holding a supply of the particulate hotmelt adhesive in a first prepackaged container including a first outletcoupled in fluid communication with a pathway leading to an inlet of aheated receiving device. The particulate hot melt adhesive is fed fromthe first outlet of the first prepackaged container through the inlet ofthe heated receiving device. The particulate hot melt adhesive from thefirst prepackaged container is heated and melted in an interior of theheated receiving device. Liquefied hot melt adhesive is directed fromthe interior of the heated receiving device to an outlet of the heatedreceiving device. The liquefied hot melt adhesive is directed from theoutlet to a hot melt adhesive dispenser. The first prepackaged containeris removed from fluid communication with the pathway, and replaced witha second prepackaged container of particulate hot melt adhesiveincluding a second outlet. The particulate hot melt adhesive is then fedfrom the second outlet of the second prepackaged container through theinlet of the heated receiving device, and the corresponding heating,melting, directing and pumping steps are performed with regard to theparticulate from the second prepackaged container.

As exemplary additional aspects, the first and second prepackagedcontainers further comprise flexible bags, and the method furthercomprises opening respective first and second covers disposed over thefirst and second outlets either during or after coupling the first andsecond prepackaged containers, respectively, to a melter.

Various additional aspects and features of the invention will becomemore readily apparent to those of ordinary skill in the art upon reviewof the following detailed description of the illustrative embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is perspective view of a melter constructed in accordance with afirst embodiment of the invention.

FIG. 2 is a perspective view of interior components of the melter shownin FIG. 1, including a first embodiment of a flexible hopper.

FIG. 3 is a perspective view similar to FIG. 2, but illustrating theflexible hopper in dash-dot lines to show interior details.

FIG. 4 is a perspective view illustrating the components shown in FIG.3, from an opposite perspective.

FIG. 5 is an elevational view, partially sectioned to show furtherinterior details and operation.

FIG. 6A is a cross sectional view similar to FIG. 5 and illustratingfurther operational details.

FIG. 6B is a cross sectional view similar to FIG. 6A, and showingfurther operational details.

FIG. 7 is a top elevational view of the melter shown in FIGS. 1 through6B.

FIG. 8 is a perspective view, cross sectioned to show the variousdetails of the melter, hot melt adhesive feed device, and flexiblehopper.

FIG. 9 is a perspective view showing another embodiment of a melter andflexible hopper.

FIG. 10A is a partially fragmented perspective view of the flexiblehopper shown in FIG. 9.

FIG. 10B is an enlarged perspective view of the feed device shown inFIG. 10A.

FIG. 10C is a perspective view similar to FIG. 10B, but illustrating thefeed device in a different position for feeding adhesive particulate tothe melter tank.

FIG. 11 is a side elevational view showing the melter of FIGS. 10A-10C.

FIG. 11A is a view similar to FIG. 11, but illustrating portions of themelter in cross section to illustrate internal components and operation.

FIG. 11B is a side elevational view, partially cross sectioned as withFIG. 11A, but illustrating further operational details.

FIG. 11C is a side elevational view, partially cross sectioned as withFIG. 11B, but illustrating further operational details.

FIG. 12 is a top view of the melter shown in FIGS. 11A through 11C.

FIG. 13 is a perspective view of another embodiment of a melterconstructed in accordance with the invention.

FIG. 14A is a perspective view of a portion of the melter shown in FIG.13.

FIG. 14B is a perspective view similar to FIG. 14A, but showing furtheroperational details.

FIG. 15A is a side view, in cross section, illustrating the melter ofFIGS. 14A and 14B.

FIG. 15B is a side cross sectional view similar to FIG. 15A, butillustrating further operational details.

FIG. 16 is a perspective view illustrating another embodiment of amelter constructed in accordance with the invention.

FIG. 17A is a perspective view of the melter shown in FIG. 16, with thecover element or lid of the melter in a closed condition.

FIG. 17B is a perspective view similar to FIG. 17A, but illustrating thecover element or lid in an open condition.

FIG. 18 is a perspective view from an alternative orientation showingthe cover in the open condition.

FIG. 18A is a perspective view of the enlarged, encircled portion ofFIG. 18.

FIG. 19A is a side cross sectional view of the melter shown in FIG. 18.

FIG. 19B is a side cross sectional view similar to FIG. 19A, butillustrating further operational details.

FIG. 20 is a top view of the melter shown in FIGS. 19A and 19B.

FIG. 21 is a perspective view of a portable container and docking andparticulate transport unit for holding and transporting particulate hotmelt adhesive to a melter, constructed in accordance with anillustrative embodiment of the invention.

FIG. 22 is a perspective view similar to FIG. 21, but illustrating theportable container being inserted into the docking and particulatetransport unit.

FIG. 22A is a perspective view similar to FIG. 22, but schematicallyillustrating a first portable container being removed and a secondportable container being inserted into the docking and particulatetransport unit.

FIG. 23A is a side cross sectional view illustrating the portablecontainer of FIGS. 21 and 22 being inserted into the docking andparticulate transport unit.

FIG. 23B is a side cross sectional view similar to FIG. 23A, but showingthe portable container fully received in the docking and particulatetransport unit.

FIG. 24 is a front cross sectional view of the portable containerreceived in the docking and particulate transport unit.

FIG. 25 is a perspective view illustrating another alternativeembodiment of a melter in combination with a prepackaged container ofparticulate hot melt adhesive.

FIG. 26 is a side elevational view of another melter similar to FIG. 25and illustrating the removal and replacement of a prepackaged containerof particulate hot melt adhesive.

FIG. 27 is a side view of a supply system.

FIG. 28 is a rear view of the supply system shown in FIG. 27.

FIG. 29 is a perspective view of the supply system shown in FIG. 27.

FIG. 30 is a cross-sectional view of a supply system with an agitatorplate.

FIG. 31 is a perspective cross-sectional view of the supply system shownin FIG. 30.

FIG. 32 is a perspective view of interior components of the supplysystem shown in FIG. 30.

FIG. 33 is a cross-sectional view of a supply system with an agitatorring.

FIG. 34 is a cross-sectional view of a supply system with an agitatorbar.

FIG. 35 is a partially-transparent perspective view of a flexible hopperwith an articulation device.

FIG. 36 is a perspective view of the flexible hopper of FIG. 35 showinga connection to a feed device and melter.

FIG. 37 is a perspective view of the flexible hopper of FIG. 35supported by a frame structure.

DETAILED DESCRIPTION

FIGS. 1 through 8 illustrate a first illustrative embodiment of a melter10 constructed in accordance with various aspects of the invention. Itwill be appreciated that like reference numbers throughout the figuresof the same or different embodiments refer to like elements ofstructure. Therefore, with regard to later embodiments, descriptions ofsuch like structure will not need to be repeated. FIG. 1 illustratesgenerally an outer housing 12 and a controller 14 with a control panel14 a for allowing an operator to control the various parameters andoperational aspects of the melter 10. The housing 12 includes a lid 18which may be opened for purposes of filling a particulate hot meltadhesive hopper 20 within the housing 12. As more specifically shown inFIGS. 2 through 4, which eliminate the outer housing 12 of the melter10, the hopper 20 comprises a flexible container or bag 22 in thisembodiment. It will be appreciated that various aspects of the melter 10may be practiced instead with a melter that uses a hopper made with aninflexible or more rigid construction. In this embodiment, the bag 22 isconstructed from a strong fabric type material, such as woven ornonwoven material that may be easily flexed without tearing or otherwiseweakening the structure of the bag 22 through repeated motions. In otherembodiments, the flexible hoppers 20 of this invention instead may beformed in multiple sections of rigid polymer, sheet metal, or othermaterials, and the sections may be coupled together for movementrelative to each other such as by the use of hinge structures. As usedherein, the term “flexible hopper” means a hopper having one or moreside wall portions capable of repeatedly moving back and forth towardand away from an opposite wall portion by a distance more than thatcaused by mere vibration. For example, the material forming a flexiblehopper wall portion is capable of moving back and forth through adistance equal to 10% or more of the total distance to an opposite wallportion without plastic deformation of the moving wall portion.

The melter 10 further comprises a heated receiving device 30, which maycomprise a melting tank having a melting grid 32 in a lower portion(FIG. 5). Generally, in this embodiment the tank 30 includes a chamber34 for receiving pellets or other particulate forms of hot melt adhesive40 (FIGS. 6A and 6B). It will be appreciated that the heated receivingdevice 30 may be a large or small tank, or may be a much smaller heatingdevice with a chamber that receives a small amount of particulate hotmelt adhesive 40 for melt-on-demand purposes. A space 42 below themelting grid 32 receives liquefied hot melt adhesive for directing theadhesive to an outlet (not shown) and then to a pump 50 and manifold 52for delivery to a suitable dispensing device or devices (not shown).

Referring further to FIGS. 5, 6A, 6B and 8, a particulate hot meltadhesive feed device 60 is mounted between an outlet 20 a at the bottomof the flexible hopper 20 and the heated receiving device 30. This feeddevice 60 may take any suitable form for carrying or otherwisedelivering the particulate hot melt adhesive 40 from the flexible hopper20 into the heated receiving device 30. It may be motorized, or it maysimply rely on gravity feed. Feed devices such as augers or otherscrew-style conveyors, belt driven devices or other conveying devicesmay be used to feed the particulate adhesive. In this embodiment thefeed device comprises a rotary valve 70 or wheel device having flexiblepaddle elements 72. The rotary valve 70 is constructed with a centralrotating member 74 coupled to a motor 76 by a belt 78 (FIG. 7). Thepaddle elements 72 are affixed to and extend generally radially outwardfrom the central rotating member 74. As shown in FIG. 3, the motor 76 isused to rotate the rotary valve 70 and a microswitch 80 is used todetect and control the various rotational positions of the rotary valve70 for purposes of determining when the rotary valve 70 rotates andstops to thereby control the feed rate of particulate hot melt adhesive40 from the flexible hopper 20 into the receiving device 30 or tank usedfor heating and liquefying the thermoplastic hot melt adhesive. Therotary valve 70 is rotated in a clockwise direction, and throughcontrolled and sequential angular movements as best depicted in FIGS. 6Aand 6B, delivers precise amounts of particulate hot melt adhesive 40 bycarrying the amounts of particulate hot melt adhesive 40 betweenadjacent paddle elements, as shown in FIG. 6B, and dropping ordelivering these amounts downwardly into an outlet of the feed device 60when prompted by the controller 14, such as when the controller 14receives a signal from a level sensor (not shown) that the tank 30 needsmore adhesive. As shown further in FIGS. 5, 6A and 6B, a flexibleskimmer flap 73 is provided in proximity to the rotary valve 70. Theflexible skimmer flap 73 is positioned above the rotary valve 70 suchthat it skims across or rides above the particulate adhesive 40 that isdeposited in each quadrant of the rotary valve 70 on the blades orpaddle elements 72. This skimming action controls the amount ofparticulate adhesive 40 in each quadrant thereby improving thevolumetric consistency of particulate hot melt adhesive 40 delivered bythe rotary valve 70. The flexible skimmer flap 73 further preventsuncontrolled flow of particular hot melt adhesive 40 over the tops ofthe blades or paddle elements 72, such as when processing a particularhot melt adhesive 40 that is free-flowing. FIGS. 5, 6A, 6B and 8 alsoshow a plurality of blade or paddle flicking elements 75. Especiallywhen processing adhesives in high ambient temperature conditions, thepotential exists for adhesives to bond to the individual flexible bladesor paddle elements 72. To help mitigate this problem, the elements 75provide bumps aligned with each paddle element or blade 72 forindividually engaging each flexible blade or paddle element 72 as itpasses during rotation of the rotary valve 70. As the blade or paddleelement 72 passes over a bump 75, it will be flexed and “flicked” suchthat it releases any adhesive particulate that is stuck to or bondedwith the paddle element 72. This feature provides a mechanism forpreventing jamming of the rotary valve 70 and to ensure that accurateamounts of particulate adhesive 40 are transferred by the valve 70.Specifically, the particulate hot melt adhesive 40 is delivered onto adownwardly inclined ramp 86. The ramp 86 is perforated and angleddownwardly toward the open top or inlet 88 of the heated receivingdevice 30. A flexible skirt of rubber, fabric or similar material 90creates a small opening 92 between a lower end 90 a of the panel 90 andthe lower end 86 a of the ramp 86 for providing a controlled flow of theparticulate hot melt adhesive 40 through the opening 92 and into theinlet or open top 88 of the heated receiving device 30 or tank. Theskirt 90 also minimizes migration of hot gases from the tank 30 into theadhesive feed device 60.

In addition, the melter 10 includes a cooling air input, which mayinclude a fan or other source for moving air 94 (FIG. 4) coupled with anair inlet supply conduit 96. The air supply conduit 96 leads to theinclined ramp 86 and, because of the perforated nature of the ramp 86,the cooling air passes through the ramp 86 and through the lower opening92 for the particulate hot melt adhesive 40. The skirt 90 is fixed tothe feed device housing along a top edge of the skirt 90, in order toleave minimal gaps along the sides of the skirt 90 and the small opening92 at the bottom, through which the cooling air travels. The cooling airthen travels across the open top 88 of the heated receiving device 30 ortank and through an outlet plenum or conduit 98. This cooling airprovides a heat transfer mechanism for carrying away the heat from theopen top 88 of the hot chamber 34. In this way, the heat emanatingupwardly from the open top 88 of the chamber 34 is directed away fromthe particulate hot melt adhesive 40 in the feed device 60, and in theflexible hopper 20. Therefore, heat from the tank 30 is less likely tocause the particulate hot melt adhesive 40 to become sticky, or evenmelt before it reaches the chamber 34.

Referring to FIGS. 2 through 8, the flexible bag 22 is attached to asuitable rigid frame structure 100. An articulation device 102 isattached to the bag 22. It will be appreciated that the articulationdevices described herein are only examples. These devices may take anyform suitable for moving the flexible hopper to maintain fluidity of theparticulate adhesive 40. In this embodiment, the articulation device 102comprises a multi-armed device 104 having end pieces 106 rigidly affixedor otherwise engaging corner portions of a generally square shaped bag22. Any other shape may be used for the bag 22 or other flexiblecontainer, and a bag articulation or deforming device may be designed inany suitable and desired manner to effect movements of the bag 22designed to break up any clumps or agglomerations of particulates 40therein. The central portions of each arm 104 a are coupled with abearing structure 107 and an eccentric drive mechanism 108 that rotatesthe central portions of the arms 104 a and the bearing structure 107. Amotor 110 is secured to a central shaft 112 and the central shaft 112 isaffixed to an eccentric coupling element 114 which then is affixed to ashort rotating shaft 116. The short rotating shaft 116 is affixed forrotation relative to a stationary fixture 120 which, in turn, is affixedto a mounting grid structure 124 (FIG. 1) near the upper opening of theflexible hopper 20. The hopper 20 may be filled with particulateadhesive 40 through the grid structure. The shafts 112, 116 and theeccentric coupling element 114 rotate slowly, such as at about 12 to 15rpm, about a central axis 130 and this rotates the center or radialinner portions of the arms 104 a. This is best shown in FIGS. 3 and 7.As the arm assembly 104 rotates, the arms 104 a effectively moveradially inwardly and outwardly as indicated by the arrows 132. Thismoves the corners of the bag 22 inwardly and outwardly toward and awayfrom opposite wall portions of the bag 22 in a generally reciprocatingmanner, however, also in a slightly rotating manner. The effect is thatthe particulate hot melt adhesive 40 within the bag 22 is moved from anouter peripheral area of the bag 22 adjacent to the bag 22 itself towarda radially inward or central area and, in the process, any clumps oragglomerated masses of the particulates 40 are broken up. In addition,the rotating shaft 112 includes a plurality of elongate paddle membersor elongate pins 136 extending generally radially outward. These paddlemembers 136 extend generally outwardly from the central axis 130 andtherefore, as the shaft 112 rotates, these paddle members 136 travelthrough the particulate hot melt adhesive 40 in a rotating fashion anddisrupt the particulate hot melt adhesive 40 at the center of theflexible bag 22. The paddle members 136 are resilient and flexible and,therefore, as the shaft 112 rotates, these paddle members 136 can bendor flex in an arc generally around the shaft 112. The paddle members 136provide scraping action as the paddles 136 force their way to a morestraightened condition until fully extended. This minimizes motor torquerequired to agitate the particulate adhesive mass 40. The combinedeffect is that any clumps or agglomerated masses of particulate hot meltadhesive 40 in the outer peripheral regions of the flexible hopper 20,or at the inner or central regions of the flexible hopper 20, are brokenapart. In this manner, the particulate hot melt adhesive 40 exiting theflexible hopper 20 at the lower end, and entering the inlet of the feeddevice 60 comprises the smallest portions broken up for purposes ofdelivery to the tank 30.

FIGS. 9 through 12 are directed to another illustrative embodiment of amelter 150. This embodiment also utilizes a flexible bag type hopper 20,which may be constructed as set forth for the first embodiment. However,the main difference is that an alternative, illustrative articulationdevice 152 is used for moving or articulating the bag 22 inwardly andoutwardly in order to move particulate hot melt adhesive 40 (not shown,for clarity) from peripheral portions of the bag interior to morecentral regions of the bag interior. In this regard, first and secondelongate elements 154, 156 are secured on opposite sides of the bag 22and include end sections 154 a, 156 a. The end sections 154 a, 156 a ofthe opposite elements 154, 156 are pivotally coupled together bypneumatic cylinders 158, 160 each having a reciprocating piston rod 162,164. The rods 162, 164 move inwardly and outwardly relative to theassociated cylinder 158, 160. The first and second elongate elements154, 156 are relatively rigid and attached to or otherwise engage theexterior of the bag 22. This is unlike the first embodiment in whichmost of the structure for articulating or moving the flexible bag 22 iscontained within the flexible hopper 20. In addition, this articulationstructure is secured to a lower portion of the bag 22, closer to theoutlet of the bag 22 to help ensure that the particulate 40 is brokenapart as close as possible to the upper inlet of the feed device 60. Inthis manner, the particulate hot melt adhesive 40 is broken up just asit exits the flexible hopper 20 and enters the feed device 60. Similarto the first embodiment, a central stirring device 170 is includedwithin the hopper 20, and generally comprises a central rotating shaft172 and a plurality of generally radially extending paddle elements 174.As with the first embodiment, this central stirring device 170 stirs andbreaks up any agglomerated masses or clumps of particulate hot meltadhesive 40 in the central regions of the flexible hopper 20 as theouter or peripheral regions of the bag 22 are flexed and moved inwardlyand outwardly by the exterior articulation device 152.

This embodiment also includes a lid or cover element 180 for the heatedreceiving device 30. This lid 180 is opened to allow controlled deliveryof the particulate hot melt adhesive 40 from the flexible hopper 20 intothe chamber 34 of the heated receiving device 30 or tank. In thisembodiment, the particulate hot melt adhesive 40 falls by gravity downand inclined ramp or chute 182 from an outlet 20 a of the flexiblehopper 20. The rotating paddle elements 174 at the lower end of theshaft 172 will continuously move the particulate hot melt adhesive 40into the chute 182. When the melter or hot melt adhesive receivingdevice 150 indicates that there is a low level of adhesive in thechamber 34, an air cylinder 184 is activated to retract a rod 186. Therod 186 is coupled with a lever 190 by way of a pivot and slotconnection 194 (see FIGS. 11A and 11B). This connection 194 ensures thatthe lid 180 opens before a gate 198 is lowered (FIG. 11C). The gate 198is coupled to the rod 186 as well but, as shown in the succession fromFIG. 11B to FIG. 11C, the lid 180 has already partially opened by thetime the gate 198 begins to open to allow particulate 40 to begin tofall down the chute 182. Particulate 40 will be prevented from fallingonto a closed lid 180 in this manner. A motor 200 may be operated forrotating the shaft 172 so as to be on and slowly rotating when the gate198 opens, such as at 15 rpm. At the same time, the piston rods 162, 164are retracted and extended to articulate the outer periphery of the bag22. When the control 14 (FIG. 1) indicates that the tank chamber 34 isfull, the motor 200 will stop operating and the rod 186 extends to closethe gate 198, and then close the lid 180 sequentially, i.e., the reverseoperation to that described above. A spring 210 is included to ensurethat in the event that there is no air pressure for the cylinder 184,the normal position for gate 198 and lid 180 will be a closed position.This stops the flow of particulate hot melt adhesive 40 before the lid180 of the tank 30 closes. Stickier particulate hot melt adhesives needmore agitation. Therefore, in embodiments that include both bag or othercontainer flexion and internal stirring, the large masses ofagglomerated particulates 40 will be broken up by the bag flexion anddirected into a central region of the bag 22, and the internal stirringdevice will break the agglomerated masses into small portions ofparticulates 40 and individual particulates. Without the bag flexion,the internal stirring elements, paddles, pins, etc. may just core outthe radially inward or central region of sticky particulate hot meltadhesive. The flexible hopper 20 may be again made of any suitable,strong flexible material such as woven or nonwoven materials, polymericmaterials, etc. For example, the fabric can be a woven fabric that isembedded in a polymer. One type of suitable fabric is sold under thebrand name Cordura®. Other heavy duty fabrics, such as ballisticmaterials, canvas materials, rip stop materials or other natural orsynthetic materials that can retain their shape and require littleoutside support, may be used instead. The air cylinders 158, 160 androds 162, 164 for constructing the articulation device 152 may becompressed in unison or out of phase with one another. For example, eachrod 162, 164 may extend and retract simultaneously, or one may beextending when the other one is retracting. Alternatively, the rod 162on one side of the bag 22 could remain stationary while the other rod164 is moving.

FIGS. 13 through 15B are directed to another illustrative embodiment ofa melter 250. In this embodiment, the flexible hopper 20 andarticulation/stirring mechanisms are configured and designed to operategenerally the same as discussed above with respect to the any of theother embodiments described herein. Therefore, further description ofthese components is not necessary. This embodiment includes a slightlydifferent feed device 60 and different lid operation for the heatedreceiving device or melting tank 30. Specifically, a downwardly inclinedchute 252 is constructed between the outlet 20 a of the flexible hopper20 and the top 88 of the heated receiving device 30. A cover element orlid 256 is provided at the top 88 of the heated receiving device 30 andis specifically constructed with two cover portions 258, 260 that arepivotally coupled to an actuation structure 264. The actuation structure264 comprises first and second linkages 270, 272 each pivotallyconnected at one end to a reciprocating element 276 and pivotallycoupled at the opposite ends to the respective cover or lid portions258, 260. The cover or lid portions 258, 260 rotate about axes definedby hinge elements 280, 282. One of the hinge elements 280 includes a cam286 that operates a microswitch 290 for indicating to the control 14(FIG. 1) when the cover or lid 256 is in the open and closed positions.This information is used by the control 14 to determine when to feedfurther particulate adhesive 40 (FIGS. 15A, 15B) into the chute 252,i.e., when to activate the rotary valve feed device 70. Pins 296 providephysical stop elements for the lid portions 258, 260 in the closedposition as shown in FIG. 13. The inner ends 258 a, 260 a of the lidportions 258, 260 are angled downwardly into the chamber 34 such that ifparticulate hot melt adhesive 40 falls on top of the lid 256, the heatedlid 256 will melt the adhesive and it will drain or drip through acentral slot 298 into the chamber. As shown in FIGS. 15A and 15B, thisembodiment also includes a rotary valve feed device 70 generally asdiscussed with regard to the first embodiment. As shown in FIGS. 15A and15B, the rotary valve feed device 70 rotates counterclockwise and eachapproximately 90 degree segment of the rotary valve movement carries anamount of particulate hot melt adhesive 40 between the adjacent paddleelements 72 and past paddle contact elements 300 such that theparticulate hot melt adhesive 40 is dumped into the chute 252. Thepaddle contact elements 300 align with the paddle elements 72 and canflex away from the paddle elements 72 as the rotary valve 70 rotates.The flexing of the paddle contact elements 300 is designed to preventthe rotary valve 70 from jamming or locking up during operation. Anotherpanel element 304 is flexible rubber, fabric or a similar material andprovides flow control for the particulate hot melt adhesive 40 at thelower outlet of the chute 252 and toward the inlet or upper opening 88of the tank 30 past the lid portions 258, 260. It will also beappreciated that the design of the rotary valve 70 in conjunction withits surrounding structure will ensure that it may be stopped at aposition as shown, for example, in FIG. 15A in which free flow ofparticulate adhesive 40 down the chute 252 will be prevented. In otherwords, at each of the four stopped positions, only one of the fourquadrants of the rotary valve 70 will be aligned and in communicationwith the chute 252. An actuator 310 for moving the lid portions 258, 260between the open and closed conditions includes a belt 312 having a pairof switch actuating elements 314, 316. The switch actuating elements314, 316 respectively contact a microswitch 320 to start and stop amotor 324, respectively, at the open and closed conditions of the lid256. The remaining portions or components of the melter 250 may be asdescribed above, or generally conventional in nature, including the pump50 and manifold 52 in fluid communication with the outlet of the heatedreceiving device 30 or tank. It will be appreciated that the tank orheated receiving device 30 may be constructed in many various forms, andsizes, depending on capacity needs, and/or melt on demand needs.

Another embodiment of a melter 330 is shown in FIGS. 16 through 20. Inthis embodiment, a flexible bag-type hopper 20 is shown and is verysimilar to the flexible hopper shown and described with regard to FIG. 1and the first embodiment. However, in this embodiment, radial arms 332of an articulation device 334 are directed toward the side portions ofthe flexible bag 22 and connecting elements 336 are affixed to orotherwise engage the flexible bag 22 essentially at central portions ofeach of the sides of the generally square bag 22. In addition, a camstructure 340 at the central region of the articulation device 334 isdesigned with four pivoting elements 342 secured to a central camelement 344 and dual bearing structure 348. Upper and lower shaftportions 352, 354 rotate about a central axis 356 and carry the camstructure 340 in an eccentric path around and spaced from the centralaxis 356. This causes the inward and outward radial bag movementgenerally as described above with regard to the first embodiment to movethe flexible bag 22 radially inward and outward during each successiverotation of the upper and lower shafts 352, 354. Again as with the firstembodiment, at least the lower shaft 354 includes generally radiallyoutward directed paddle elements 360 that stir and break up centralregions of the particulate hot melt adhesive 40 before the adhesiveenters the feed device 60. As shown in FIGS. 19A and 19B, the rotaryfeed device 70 is constructed in a manner similar to the rotary valvespreviously described. In this embodiment, however, the paddle elements72 contact a projection 364 for flexing the paddle elements 72 duringeach approximately 90 degrees of rotation. A stationary panel member368, in the form of a flexible curtain or skirt, provides a flow controland a lower, small outlet 370 in a chute 374 leading to an upper end 88of the tank 30, generally as previously described. The lower, smalloutlet 370 is defined by the rigid surfaces of the chute 374 on thebottom and sides and by the flexible curtain 368 at the top. In thisembodiment, the tank or heated receiving device 30 includes a pivotallid 380 that is raised and lowered between open and closed conditions bya belt 382 and motor 384. A microswitch 386 is used to indicate the openand closed conditions to the control 14 (FIG. 1). This microswitch 386is used to control operation of the motor 384 for allowing particulatehot melt adhesive 40 to enter the tank 30 when the lid 380 is open. Theoperation of the motor 384 for actuating the lid 380 is coordinated withthe operation of the feed device 60 to ensure that the lid 380 is openedbefore the feed device 60 is operated to send a further amount ofparticulate hot melt adhesive 40 down the chute 374 and into the tank30. The flexible curtain 368 blocks heat from emanating into the chute374 and toward the outlet 20 a of the flexible hopper 20. This creates athermal break for helping to prevent melting or softening of theparticulate hot melt adhesive 40. When the lid 380 is in the closedcondition, as shown in FIG. 16, two lid portions 380 a, 380 b are angleddownwardly toward edges 380 c of each lid portion 380 a, 380 b and thelid portions angle both toward each other and toward a notch 388 whichacts as a drain. Therefore, if any particulate adhesive falls from thechute 374 onto the closed lid 380, the particulate 40 will melt anddrain through the notch 388 into the tank 30.

Referring generally to FIGS. 21, 22 and 22A, in another embodiment anapparatus 410 includes a docking and particulate transfer unit 412 and acontainer 414 constructed in accordance with an illustrative embodimentof the invention. As shown in FIG. 22, the container 414 holdsparticulate hot melt adhesive 40 and is inserted into a containerreceiving space 418 of the docking and particulate transfer unit 412.The container 414 may be sized to hold an amount of adhesive 40 equal toa specific time period of use, such as one production shift. Thecontainer receiving space 418 is defined by a pair of curved sidewalls420, 422 converging toward a lower end. A piercing member 424 of theunit 412 is fixed at the lower end of the container receiving space 418for purposes to be described below. The curved sidewalls 420, 422 definea central slot 430 which is configured to receive an elongate protrudingsegment 432 of the container 414 as shown in FIG. 21. At least thisexposed segment 432 of the container 414 is transparent or at leasttranslucent so that an operator can see the level of particulate hotmelt adhesive 40 in the container 414. The container 414 has a shapewhich is generally complementary to the shape of the internal containerreceiving space 418 so that a snug fit is formed between the container414 and the docking and particulate transfer unit 412. The container 414includes a flat rear wall 440 that engages or is parallel to an interiorrear surface 442 of the docking and particulate transfer unit 412. Thedocking and particulate transfer unit 412 further includes a flatexterior, rear surface 444 with suitable structure (not shown) forhanging the unit 412 on a wall 446 (FIGS. 23A and 23B). As furtherdiscussed below, and illustrated schematically in FIG. 22A, a firstcontainer 414 may be removed from the unit 412, such as when it isdepleted of unmelted particulate hot melt adhesive 40, and then replacedby a second container 414 a of particulate hot melt adhesive 40. Ifempty, the first container 414 may be discarded or recycled if it is asingle-use, disposable or recyclable container or it may be refilled, asdesired.

As further shown in FIGS. 22, 23A and 23B, the particulate container 414includes a lower, generally cylindrical end 460 which registers withinthe lower end of the container receiving space 418. The end 460 includesthreads 460 a that receive an internally threaded cap 461 (FIG. 22). Thecap 461 is used while storing and transporting the container 414 ofparticulate adhesive 40 and is removed prior to inserting the container414 into the unit 412. The piercing member 424 pierces a rupturableelement or membrane 462 covering a lower end or outlet opening 464 ofthe container 414 such that the interior of the container 414 and itsparticulate contents 40 communicate with a vertically oriented conduit470. The particulate adhesive 40 flows by gravity through the verticalconduit 470 and then into a generally horizontally oriented conduit 472.As further shown in FIGS. 21, 22 and 23B, the container 414 includes ahandle 480 coupled with a lid or cover 482 at an upper end of thecontainer 414 as another manner to access the interior of the container414.

FIG. 24 schematically illustrates the operation of transporting ormoving the particulate adhesive 40 in the container 414 through theoutlet opening 464 and into the vertical conduit 470. The particulateadhesive 40 is further moved, such as by using a pneumatic air movingdevice or eductor 490 in the direction shown by the arrows 492 throughthe generally horizontal conduit 472 to a melter 494 (FIG. 21). Theconduit 472 may include one or more different types of conduit and theseconduits may be rigid and/or flexible. For example, a flexible hose 496may be used of any suitable length to direct the particulate adhesive tothe melter 494, as needed, to operate the melter 494 during a dispensingoperation.

As best illustrated in FIG. 22A, one illustrative embodiment provides asystem for holding and transferring unmelted particulate hot meltadhesive from a plurality of containers 414, 414 a, used one after theother, to the melter (FIG. 21). In this type of system, the unit 412 isused to hold a first container 414 as previously described. When it isdesired to remove that container 414 because the container is depletedof unmelted particulate hot melt adhesive or for other reasons, thatcontainer 414 is removed from the unit 412 and replaced by a newcontainer 414 a of unmelted particulate hot melt adhesive 40. It will beunderstood that the containers 414, 414 a illustrated herein are merelyexamples of the constructions, configurations and shapes that arepossible. The containers 414, 414 a may take on many optional forms, andmay be formed as rigid containers, semi-rigid containers, or evenflexible containers such as bags. If a flexible container or bag is usedas the container 414, 414 a, it may be formed of various flexiblematerials, such as reinforced fabric or mesh materials formed frompolymer or other synthetic material. The unheated docking andparticulate transfer unit 412 is thermally isolated from other heatedcomponents of a hot melt adhesive dispensing system, such as the heatedmelter 494 (FIG. 21). It is important to note that the unmeltedparticulate hot melt adhesive 40 in the containers 414, 414 a remainsunsoftened and unmelted by any external heat source, such as other hotmelt adhesive systems components. The first and second containers 414,414 a may be single use containers which are discarded or recycled afterthe unmelted particulate hot melt adhesive 40 is transferred from thecontainer 414, 414 a. Further, it will be appreciated that manydifferent designs of mechanisms for opening the outlet 464 of thecontainers 414, 414 a may be used. For example, as options to therupturable element 462, various types of movable gate mechanisms orother selectively actuating covering elements may be used instead. Suchcovering elements may be selectively moved between open and closedpositions. Other single use covering elements, other than the rupturableelement 462, may be used to carry out embodiments of the invention.

FIG. 25 illustrates another alternative embodiment of a melter 500utilizing a prepackaged container 414 a′ of particulate adhesive 40. Inthis regard, instead of coupling the prepackaged container 414 a′ to aremote unit for delivering the particulate adhesive to a melter, theprepackaged container 414 a′ of particulate adhesive is coupled directlyto the melter 500. For example, the container 414 a′ of particulate hotmelt adhesive 40 may be inserted directly into a receiving unit 502 suchthat an outlet 504 of the container 414 a′ communicates with a suitableparticulate hot melt adhesive feed device, such as one of the feeddevices 60 described hereinbefore, or another suitable feed device. Thefeed device 60 then directs the particulate hot melt adhesive 40 into amelting tank 30, such as generally as previously described. Thecontainer 414 a′ shown in FIG. 25 is rigid, however, it will beappreciated that any of the flexible hoppers or containers as describedherein may be used instead. The lower end or outlet 504 of the container414 a′ has a suitable cover element (not shown) that may be opened, suchas described in the previous embodiment or in any other suitable manner.For example, the cover element may be capable of selectively beingopened and closed by a user in accordance with intermittent needs of theparticular application.

FIG. 26 schematically illustrates another embodiment of a prepackagedcontainer 510 of particulate hot melt adhesive 40 coupled with a melter512. In this embodiment, an outlet cover element 514 is a rupturableelement at the lower end of the container 510 and a piercing element 520associated with the melter 512 is used to open the outlet of thecontainer 510 as the container 510 is inserted thereby facilitatingcommunication between the interior of the container 510 and the contentsof the particulate hot melt adhesive 40 and a feed device 60. The feeddevice 60 is coupled with a suitable heated receiving device 522, suchas a hot melt adhesive melt-on-demand device. It will be appreciatedthat the outlet of the prepackaged container 510 may include any othertype of cover element appropriate for sealing and covering the outlet ofthe container 510 during shipping and storage, but capable of beingopened either simultaneously with the insertion of the container 500into a receiving component or simultaneous with some other type ofcoupling of the container 510 to the melter 512. Or, the cover element514 may be capable of being opened by a user after the prepackagedcontainer is coupled with the melter.

FIGS. 27 through 34 depict illustrative embodiments of a hot meltadhesive supply system 610 (the “supply system,” hereinafter) includinga lateral agitator. In general, the supply system 610 is configured toreceive a supply of hot melt adhesive particulate and provide theadhesive particulate to an attached adhesive melter. The adhesivemelter, in turn, may provide melted hot melt adhesive to an adhesivedispensing module.

Referring to FIGS. 27 through 29, the supply system 610 may include arigid outer housing 612. In some aspects, the outer housing 612 mayfully or substantially enclose the components therein. For example, theouter housing 612 may be formed from a plastic bin. In other aspects,the outer housing 612 may not fully enclose the internal components ofthe supply system 10. For example, the outer housing 612 may becomprised of a structural frame with open sides. A lid 618 may behingedly attached to the top of the outer housing 612. Further, one ormore wheels 616 may be attached to a bottom portion of the outer housing612 to facilitate movement of the supply system 610.

The outer housing 612 may include a transfer hose connection 614 throughwhich adhesive particulate may be suctioned or otherwise discharged fromthe supply system 610. The transfer hose connection 614 may be aconnection piece that allows the supply system 610 to connect to andsupply a separate device with adhesive particulate. The transfer hoseconnection 614 may be configured to create a seal with the separatedevice, such as a melter, such that suction is created between thesupply system 610 and the separate device, thus allowing for thedischarge of adhesive particulates.

Referring to FIGS. 30 through 32, which further depict internalcomponents of the supply system 610, a flexible inner housing 640 (notshown in FIGS. 31 and 32) is disposed within the outer housing 612 toreceive the adhesive particulate. The flexible inner housing 640 may beformed as a bag or similar shape and constructed from a fabric or otherflexible material that is suitably durable to sustain repeated motionswithout tearing or weakening. The flexible inner housing 640 at leastpartially defines an inner cavity 630 in which the adhesive particulateis held and dispensed from. In some aspects, the inner cavity 630 may bepartially defined by the outer housing 612 and partially defined by theflexible inner housing 640. A top opening 631 of the flexible innerhousing 640, and thus also of the inner cavity 630, may be defined by aperiphery of a top portion 632 of the flexible inner housing 640. Theadhesive particulate may be supplied to the flexible inner housing 640via the top opening 631.

The flexible inner housing 640 may be supported by the outer housing612. For example, the top portion 632 of the flexible inner housing 640may be affixed to the outer housing 612 while side portions 633 and abottom portion 634 of the flexible inner housing 640 remain un-affixedto the outer housing 612. An outer cavity 635 may be defined between theflexible inner housing 640 and the outer housing 612.

A suction lance 643, which may include an elongated hollow tube, isconnected to the transfer hose connection 614 at an upper end andsituated within the inner cavity 630 at a lower end. At the lower end ofthe suction lance 643, a transfer pump 646 having a transfer opening 650provides suction or other motive means to cause, at least in part, thetransfer of adhesive particulate from the inner cavity 630 to anattached device through the transfer hose connection 614. In someaspects, the suction or other motive means may be provided additionallyor alternatively by a pump or other mechanism at the transfer hoseconnection 614 or further downstream from the transfer hose connection614.

An agitator 636 facilitates movement of adhesive particulate within theinner cavity 630 and/or prevents clumping and sticking of adhesiveparticulate. In the embodiment depicted in FIGS. 30 through 32, theagitator 636 includes one or more elongated agitator plates 642 situatedin the outer cavity 635 external to and on opposite sides of theflexible inner housing 640. The agitator plates 642 may be coupled, atrespective elongate ends 642 a, to one another or another structure inthe outer housing 612 via one or more actuators 641, such as pneumaticor hydraulic actuators. Each actuator 641 may include a cylinder 648 anda reciprocating rod 649. The agitator 636, including the one or moreagitator plates 642 and one or more actuators 641, may preferably besituated above (i.e., closer to the top portion 632 of the flexibleinner housing 640) the transfer opening 650 of the transfer pump 646.

Upon the reciprocating operation of the one or more actuators 641, theagitator plates 642 may laterally engage with the side portions 633 ofthe flexible inner housing 640 to manipulate the shape of the flexibleinner housing 640 and, thus, the adhesive particulate therein. Theexternal lateral forces imparted upon the adhesive particulate by theagitator plates 642 may serve to prevent undesirable bridging or“ratholing” near the transfer opening 650 of the transfer pump 646 ofthe suction lance 643 and/or prevent or break up clumping of adhesiveparticulate before it reaches the area of the inner cavity 630 (e.g.,the area proximate the bottom portion 34 of the flexible inner housing40) from which the transfer pump 646 draws adhesive particulate. Forexample, “ratholing” may occur when a central void forms above thetransfer opening 650 of the transfer pump 646 while adhesive particulatealong the circumferential periphery of the inner cavity 630 fails toflow into the central void. The lateral force and manipulation caused bythe actuation of the agitator plates 642 urges the adhesive particulatealong the circumferential periphery of the inner cavity 630 to move toand fill in the central void and thus be suctioned into the transferopening 650 of the transfer pump 646.

To further facilitate movement of adhesive particulate within the innercavity 630, the transfer pump 646 may be configured with a vibrator 644and pins 645. The vibrator 644 causes the transfer pump 646 and attachedpins 645 to vibrate, thus agitating any adhesive particulate locatednear the transfer pump 646. The pins 645 may be affixed to the transferpump 646 around a periphery of the transfer opening 650 and extend in adirection generally parallel to an elongate axis of the transfer pump646 and/or the suction lance 643.

A vertical agitator 647 may be disposed in the outer cavity 635 betweenthe bottom portion 634 of the flexible inner housing 640 and the bottomof the outer housing 612. The vertical agitator 647 may engage thebottom portion 634 of the flexible inner housing 640 to agitate by, forexample, vertical oscillations, the adhesive particulate therein. Forexample, the vertical agitator 647 may include a vertical agitator plate652 operatively connected to a vertical actuator 654. The verticalactuator 654 may be configured to vertically oscillate (i.e., indirections generally towards and away from the top opening 631 of theflexible inner housing 640) the vertical agitator plate 652, which is incontact with the bottom portion 634 of the flexible inner housing 640.The vertical oscillation of the vertical agitator plate 652 causesagitation of the adhesive particulate within the flexible inner housing640, particularly the adhesive particulate proximate the transferopening 650 of the transfer pump 646, to facilitate flow of the adhesiveparticulate into the transfer pump 646.

FIG. 33 depicts an alternative embodiment of the supply system 610 inwhich the agitator 636 comprises an agitator ring 670, which may becircular, elliptical, or other generally round shape. The agitator ring670 may be disposed in the outer cavity 635 between the outer housing612 and the flexible inner housing 640 such that the agitator ring 670may at least partially contact the flexible inner housing 640. Theagitator ring 670 may be configured to rotate eccentrically around theflexible inner housing 640 such that the agitator ring 670 applies alateral force to the flexible inner housing 640. Due the eccentricrotation of the agitator ring 670, the circumferential point of theflexible inner housing 640 at which the agitator ring 670 applies alateral force to the flexible inner housing 640 will be continuouslyvaried. The lateral force applied by the agitator ring 670 causesadhesive particulates inside of the flexible inner housing 640 toagitate, urging the adhesive particulates to drop down to the transferpump 646 and be discharged.

In an aspect, the agitator 636 may include multiple agitator rings 670.The multiple agitator rings 670 may be configured to rotateeccentrically in concert with each other, in a specified pattern orsequence, or in an unrelated manner (e.g., the rotation of a firstagitator ring 670 is out of sync with a second agitator ring 670). Eachagitator ring 670 may rotate at the same speed or variable speeds (e.g.,a first agitator ring 670 rotates at a different speed as that of asecond agitator ring 670). Similarly, the agitator rings 670 may beformed in the same shape or different shapes. It will be appreciatedthat agitator rings 670 that are not perfectly round may rotate on afixed axis and still accomplish the desired function in agitating theadhesive particulates inside of the flexible inner housing 640.

FIG. 34 depicts an alternative embodiment of the supply system 610 inwhich the agitator 636 includes one or more agitator bars 680. Asindicated by the corresponding arrows, the one or more agitator bars 680may each move generally vertically up and down in the outer cavity 635between the outer housing 612 and the flexible inner housing 640. Duringat least a portion of the vertical travel of the one or more agitatorbars 680, the one or more agitator bars 680 may be in contact with theflexible inner housing 640. The one or more agitator bars 680 may bespaced from one another or an opposite side wall of the outer housing612 such that as the one or more agitator bars 680 move vertically upand down, the flexible inner housing 640 therebetween is compressed,thus causing a lateral force to the adhesive particulate within thecorresponding portion of the inner cavity 630 and facilitating itsmovement.

The agitator 636 may include one or multiple agitator bars 680. Theagitator bars 680 may be of varying cross-sectional shapes, such asround, square, triangular, etc. and may be straight, curved, or othershape. The agitator bars 680 may each be formed as a roller. Inembodiments with multiple agitator bars 680, the agitator bars 680 maymove up and down in concert with each other, in a specified pattern orsequence, or in an unrelated manner. For example, the agitator bars 680may be configured such that one more upwards while another movesdownward and vice versa. The agitator bars 680 may move at the samespeed or at variable speeds.

It will be appreciated that the various agitation components of thesupply system 610, such as the agitator 636, the agitator plates 642,the vibrator 644, the pins 645, the vertical agitator 647, the agitatorring 670, and/or the agitator bars 380, may be operated sequentially,concurrently, or in concert in a predetermined pattern. For example, inthe embodiment depicted in FIGS. 32 through 33, the agitator plates 642may be initially operated following an extended period of disuse of thesupply system 610 to break up any agglomerations of adhesive particulatethat formed during the period of disuse. During this initial period ofagitator plate 642 operation, the vibrator 644 and the vertical agitator647 may remain idle. After the agglomerations of adhesive particulateare broken up and the supply system 610 is ready to supply adhesiveparticulate, the agitator plates 642, the vibrator 644, and the verticalagitator 647 may all operate simultaneously. As another example, theagitator plates 642 and vibrator 644 may be configured to operate suchthat the vibrator 644 does not vibrate during the compressive stroke ofthe agitator plates 642 but does vibrate during the expansive stroke ofthe agitator plates 642.

FIG. 35 depicts an illustrative embodiment of an independent flexiblehopper 702, having a plurality of side walls defining an interior, thatis configured to hold a supply of particulate hot melt adhesive. Theside walls of the flexible hopper 702 are depicted as transparent inFIG. 35 so that the various other components may be visualized. Theflexible hopper 702 includes an aperture 704 defining an outlet 706through which the particulate hot melt adhesive may be supplied, such asto another device. In some aspects, the aperture 704 may be positionedin a bottom surface of the flexible hopper 702 (as shown in FIG. 35) sothat the flow of particulate hot melt adhesive through the outlet 706 isgenerally in a direction parallel with the longitudinal axis of theflexible hopper 702. While in other aspects, the aperture 704 may bepositioned at the bottom of one of the plurality of side walls so thatthe flow of particulate hot melt adhesive through the outlet 706 isgenerally in a direction perpendicular to the longitudinal axis of theflexible hopper 702.

The flexible hopper 702 further includes an articulation device 708,such as the articulation device 102 depicted in FIGS. 2 through 5, thatis operable to move a section of a side wall of the flexible hopper 702relative to another section of the side wall. This movement of thesection of the side wall may move a portion of the particulate hot meltadhesive that is adjacent to the side wall towards a central interiorlocation of the flexible hopper 702.

The flexible hopper 702 is configured with a coupling element 710, whichmay include the aperture 704, to connect the flexible hopper 702 withanother device, such as a melter or an intermediate distribution or feeddevice connected to a melter, that receives the particulate hot meltadhesive supplied from the flexible hopper 702. For example, FIG. 36depicts the connection of the flexible hopper 702, via the couplingelement 710, with a feed device 720 which, in turn, is connected to amelter 722.

As shown in FIG. 37, the flexible hopper 702 may be supported by a framestructure 730. The frame structure 730 may be configured such that a topportion 732 of the frame structure 730 accommodates and supports theflexible hopper 702 and a bottom portion 734 of the frame structure 730accommodates a device, such as a melter or an intermediate feed deviceconnected to a melter, that receives the particulate hot melt adhesivefrom the flexible hoper 702.

While the present invention has been illustrated by the description ofspecific embodiments thereof, and while the embodiments have beendescribed in considerable detail, it is not intended to restrict or inany way limit the scope of the appended claims to such detail. Thevarious features discussed herein may be used alone or in anycombination. Additional advantages and modifications will readily appearto those skilled in the art. The invention in its broader aspects istherefore not limited to the specific details, representative apparatusand methods and illustrative examples shown and described. Accordingly,departures may be made from such details without departing from thescope or spirit of the general inventive concept.

What is claimed is:
 1. A flexible bag system configured to dispenseparticulate hot melt adhesive, the flexible bag system comprising: aflexible bag body having an outer surface and an inner surface, theflexible bag body being configured to hold the particulate hot meltadhesive; an outlet in fluid communication with the interior of theflexible bag body, the outlet being configured to output particulate hotmelt adhesive to a melter; and an articulation device in contact withthe flexible bag body, and configured to manipulate the flexible bagbody to maintain fluidity of the particulate hot melt adhesive out ofthe outlet.
 2. The flexible bag system of claim 1, wherein thearticulation device is within the flexible bag body and contacts theinner surface of the flexible bag body.
 3. The flexible bag system ofclaim 2, wherein the articulation device comprises one or more endpieces connected to a drive mechanism by one or more corresponding arms,the one or more end pieces being coupled to the inner surface of theflexible bag body.
 4. The flexible bag system of claim 3, wherein thedrive mechanism is an eccentric drive mechanism that rotates the one ormore arms to manipulate the flexible bag body.
 5. The flexible bagsystem of claim 3, wherein the drive mechanism is a vibrator mechanismthat vibrates the one or more arm to manipulate the flexible bag body.6. The flexible bag system of claim 1, wherein the articulation deviceis outside of the flexible bag body and contacts the outer surface ofthe flexible bag body.
 7. The flexible bag system of claim 6, whereinthe articulation device comprises one or more elongate elementsconnected to a drive mechanism, the one or more elongate elementscontacting the outer surface of the flexible bag body.
 8. The flexiblebag system of claim 7, wherein the drive mechanism is a pneumaticcylinder that linearly shifts the one or more elongate elements tomanipulate the flexible bag body.
 9. The flexible bag system of claim 1,wherein the outlet comprises one or more paddles radially extending froma central shaft that, when rotated, disrupt the particulate hot meltadhesive.
 10. The flexible bag system of claim 1, wherein the flexiblebag body defines an upper opening configured to receive the particulatehot melt adhesive.
 11. The flexible bag system of claim 1, wherein theflexible bag body defines an opening to release the particulate hot meltadhesive.
 12. The flexible bag system of claim 1, wherein the flexiblebag body is prepackaged with the particulate hot melt adhesive.
 13. Theflexible bag system of claim 12, wherein the flexible bag body is sealedenclosing the particulate hot melt adhesive.
 14. The flexible bag systemof claim 1, wherein flexible bag body is made of a fabric.
 15. Theflexible bag system of claim 14, wherein the fabric is a woven fabricembedded in a polymer.
 16. A system for supplying particulate hot meltadhesive, the system comprising: an outer housing comprising a transferopening through which the particulate hot melt adhesive is transferred;and the flexible bag system of claim 1 connected to the outer housing,wherein the transfer opening is in fluid communication with the outletin fluid communication with the interior of the flexible bag body. 17.The system of claim 16, wherein the transfer opening is configured tooutput particulate hot melt adhesive to a melter.
 18. The system ofclaim 16, wherein the flexible bag system is removably connected to theouter housing.
 19. The system of claim 18, wherein the removablyconnected flexible bag body is prepackaged with the particulate hot meltadhesive.
 20. The system of claim 19, wherein the outer housing furthercomprises a piercing element that is configured to form an opening inthe flexible bag body when the flexible bag system is connected to theouter housing.
 21. A melter for heating and melting particulate hot meltadhesive into a liquefied form, the melter comprising: a heatedreceiving device having an interior with an inlet configured to receivethe particulate hot melt adhesive and an outlet, the heated receivingdevice operative to heat and melt the particulate hot melt adhesive, anddirect the hot melt adhesive as a liquefied form to the outlet; and theflexible bag system of claim 1 connected to the heated receiving device.22. The melter of claim 21, wherein the flexible bag system is outsideof a heated flow path of the heated receiving device.
 23. The melter ofclaim 22, wherein the outlet of the flexible bag system is thermallyinsulated from the inlet of the heated receiving device.
 24. The melterof claim 21, wherein the flexible bag system is located above the inletof the heated receiving device, and the outlet of the flexible bagsystem is in intermittent fluid communication with the inlet of theheated receiving device.
 25. The melter of claim 21, further comprisinga rotary valve located between the outlet of the flexible bag system andthe inlet of the heated receiving device, the rotary valve configured tointermittently provide some of the particulate hot melt adhesive to theinlet of the heated receiving device.
 26. The melter of claim 25,wherein the rotary valve is configured to thermally insulate the outletof the flexible bag system from the inlet of the heated receivingdevice.
 27. The melter of claim 26, wherein the rotary valve comprisesone or more flexible paddle elements that are configured to thermallyinsulate the outlet of the flexible bag system from the inlet of theheated receiving device.
 28. The melter of claim 21, wherein theflexible bag system is located of a side of the heated receiving device,and the outlet of the flexible bag system is adjacent to and in fluidcommunication with the inlet of the heated receiving device.
 29. Themelter of claim 21, wherein the flexible bag system is within theinterior of the heated receiving device.
 30. The melter of claim 21,wherein the flexible bag system is removably connected to the heatedreceiving device.
 31. The melter of claim 30, wherein the removablyconnected flexible bag body is prepackaged with the particulate hot meltadhesive.
 32. The melter of claim 31, wherein the heated receivingdevice further comprises a piercing element that is configured to forman opening in the flexible bag body when the flexible bag system isconnected to the heated receiving device.
 33. A system for supplyingparticulate hot melt adhesive, the system comprising: an outer housing;a flexible inner housing disposed inside the outer housing andconfigured to receive the particulate hot melt adhesive; a transferopening disposed inside the flexible inner housing and through which theparticulate hot melt adhesive is transferred; and an agitator in contactwith the flexible inner housing, the agitator configured to apply alateral force to a surface of the flexible inner housing.
 34. The systemof claim 33, wherein the agitator comprises an agitator plateoperatively coupled with an actuator.
 35. The system of claim 34,wherein the agitator plate comprises a first agitator plate and a secondagitator plate, the actuator operatively coupling the first agitatorplate and the second agitator plate such that upon operation of theactuator, the first agitator plate moves relative to the second agitatorplate.
 36. The system of claim 35, wherein the first agitator plate andthe second agitator plate are positioned at opposite sides of theflexible inner housing.
 37. The system of claim 35, wherein the firstagitator plate and the second agitator plate are situated in theflexible inner housing at a vertical position above the transferopening.
 38. The system of claim 33, wherein the transfer opening issituated proximate a bottom portion of the flexible inner housing. 39.The system of claim 38, further comprising: an elongated suction lanceinterposed between the transfer opening and a transfer hose connection,the transfer hose connection configured to connect to a device toreceive the particulate hot melt adhesive from the system.
 40. Thesystem of claim 39, wherein the suction lance comprises a transfer pumpconfigured to supply a negative pressure to transfer particulate hotmelt adhesive through the suction lance.
 41. The system of claim 39,wherein the suction lance further comprises a vibrator.
 42. The systemof claim 39, wherein the transfer opening is configured with a pluralityof elongated pins, each of the plurality of elongated pins extendingfrom the transfer opening in a direction generally parallel of anelongate axis of the suction lance.
 43. The system of claim 33, whereinthe system further comprises: a vertical agitator in contact with abottom portion of the flexible inner housing, the vertical agitatorconfigured to apply vertical oscillations to the bottom portion of theflexible inner housing.
 44. The system of claim 43, wherein the verticalagitator comprises an agitator plate operatively coupled with a secondactuator, the agitator plate contacting the bottom portion of theflexible inner housing during the vertical oscillations.
 45. The systemof claim 33, wherein the agitator comprises an agitator ring in contactwith the flexible inner housing, the agitator ring configured to applythe lateral force to the flexible inner housing upon rotation of theagitator ring.
 46. The system of claim 45, wherein the agitator ring isconfigured to rotate eccentrically.
 47. The system of claim 45, whereinthe agitator ring is has an elliptical shape.
 48. The system of claim45, wherein the agitator ring comprises a first agitator ring and asecond agitator ring, each in contact with the flexible inner housing.49. The system of claim 48, wherein the first agitator ring and thesecond agitator ring are differently shaped.
 50. The system of claim 48,wherein the first agitator ring and the second agitator ring rotate atdifferent speeds.
 51. The system of claim 48, wherein the first agitatorring and the second agitator ring rotate in sync with each other. 52.The system of claim 48, wherein the first agitator ring and the secondagitator ring rotate out of sync with each other.
 53. The system ofclaim 33, wherein the agitator comprises an agitator bar configured tomove in a generally vertical direction, wherein movement of the agitatorbar applies the lateral force to the flexible inner housing.
 54. Thesystem of claim 53, wherein the agitator bar comprises a first agitatorbar and a second agitator bar each configured to move in the generallyvertical direction.
 55. The system of claim 54, wherein the firstagitator bar and the second agitator bar are each configured with aroller.
 56. The system of claim 54, wherein the first agitator bar andthe second agitator bar move in concert with each other.
 57. The systemof claim 54, wherein the first agitator bar is configured to move upwardwhen the second agitator bar moves downward.
 58. The system of claim 54,wherein the first agitator bar and the second agitator bar areconfigured to move at different speeds.